Plant-based food manufacturers aren’t just targeting vegan and vegetarian consumers, either. Sales of meat alternatives are also being driven by an increasing number of “flexitarians” who are incorporating more plant-based foods into their meat-eating diets.

Thanks to all of this buzz, what was once just a niche market has now become more crowded. That means manufacturers of plant-based proteins and other animal-free foods are being forced to rethink how they can scale and remain competitive.

Let’s look at five questions plant-based food manufacturers should ask if they want to grow while staying cost-conscious.

1. Am I ready to invest in equipment and automation?

Given the new popularity of meat alternatives, manufacturers can’t just focus on the smaller market of consumers who have been willing to pay higher prices for a niche product. If a plant-based protein producer wants to reach a wider audience, its prices must be more competitive to appeal to the mass market.

For many smaller manufacturers, scaling up to meet that price point often means investing in additional equipment and/or automation because their current process may be basic and manual. For example, we recently worked with one plant-based startup that was developing and testing products in what was essentially a commercial kitchen. Introducing these products to a greater labor process allows these manufacturers to be more competitive.

Plus, flexitarians and traditional meat-eaters value taste and texture that is more familiar. In order to appeal to this broader consumer base, these companies may need to consider more advanced equipment to achieve that texture with a plant-based product.

2. Do I understand federal food safety regulations?

Startup food companies may not be familiar with all of the regulations that come with large-scale manufacturing. Usually, the entrepreneurs creating these foods are experts in the formulation of their product, not necessarily in the intricacies of commercializing it.

While the U.S. Department of Agriculture (USDA) has regulatory jurisdiction over the majority of meat and animal products, the U.S. Food and Drug Administration (FDA) oversees most plant-based food products, even plant-based “meats.”

However, the USDA does regulate egg products, so there may be some plant-based options that fall under USDA jurisdiction if they contain egg (i.e., are not vegan).

When taking your food production to the next level, it’s critical to understand the food safety regulations and requirements for your specific processing, because they can vary widely.

3. What distribution plan will I need?

Increasing your production and distribution usually requires more space. When stepping up your output, consider whether you have enough space to store your product before it’s handed off to a distributor or delivered to the consumer. An experienced partner can help you develop a strategy for your package engineering, storage and supply chain.

4. How do I engineer efficient processing?

When it comes to the nuts and bolts of your processing lines and product flow, a lot will likely change when growing your business.

How much space will you need?

How much equipment will be required?

What size equipment will be necessary?

How will packaging needs change?

It’s important to understand exactly what equipment you need and in what quantities to prevent bottlenecking, while also building in modular flexibility to adapt for future growth.

We often work with clients who have an idea of where they want their business to be in five years, but may not know exactly how to get there. Our team is able to analyze current operations against future projections to develop a roadmap of how to achieve that future growth, including what capital investments will be required and when.

5. Am I already considering a new facility?

Before rushing into selecting a new facility, partner with a firm who can help you understand what space you’ll need to accommodate your processing. We’ve worked with clients who invested in a spec warehouse first, only to realize that it wouldn’t suffice for the future growth they were anticipating.

]]>http://stellarfoodforthought.net/how-to-capitalize-on-the-demand-for-plant-based-foods/feed/0What is Total Package Oxygen in Beer?http://stellarfoodforthought.net/what-is-total-package-oxygen-in-beer/
http://stellarfoodforthought.net/what-is-total-package-oxygen-in-beer/#respondThu, 16 May 2019 10:00:59 +0000http://stellarfoodforthought.net/?p=3818

Managing total package oxygen (TPO) can be a challenge for beer producers looking to grow their output. TPO is the total concentration of oxygen (O2) present in packaged beer at the time of packaging. When beer comes into contact with air, it begins to oxidize — and too much oxygen can negatively affect the beer’s flavor.

The ultimate goal is to reduce the amount of oxygen allowed in during packaging to prevent oxidation and maintain product quality and taste. However, this can be easier said than done, especially if you’re transitioning from a smaller-scale production with manual processes to greater throughput with increased automation.

The source of packaged oxygen

Packaged oxygen can come in the form of:

1. Dissolved oxygen (DO) — This is the oxygen present in the beer before filling, plus any oxygen picked up during the filling process

2. Headspace oxygen (HO) — This is the air left over in the headspace after a closure is placed on the bottle or can

As a smaller brewery transitions to larger-scale processing, it’s critical to invest in packaging equipment that can handle the projected volume while maintaining product quality. In most instances, the higher your fill rates, the greater concern there is for packaged oxygen.

In short: The faster the filling process moves, the more agitation occurs with the liquid. The more agitation that occurs with carbonated beverages, the more control you will need to maintain package and product integrity.

Modified atmosphere packaging

One solution to help control packaged oxygen is modified atmosphere packaging, which is the process of dosing the space under the enclosure with an inert gas — in most cases, nitrogen (N2) — prior to it being sealed. This practice helps displace oxygen before the final primary package is sealed.

After packaging, beer sold in bottles is still susceptible to additional exposure of oxygen leaking through crown closures. That’s why minimizing the initial TPO is critical to maximizing the product’s shelf life.

Today, automated measuring devices can accurately measure TPO as well as other variables in your beer during production runs. It’s critical to monitor these levels periodically according to your processing output to ensure quality control.

You’ve likely heard a lot about Industry 4.0 and the impact of predictive and prescriptive maintenance on the food and beverage industry. It can sound overwhelming, but it doesn’t have to be. In fact, a few basic investments and the right partner can help streamline the way your facility operates and communicates

Food manufacturing facilities are complex and have various ecosystems operating at different levels, including:

But all of these systems don’t always talk to each other. In many facilities, an equipment failure triggers a lengthy domino effect: Maintenance staff has to assess the problem, create a work order, check if a replacement part is available and so on.

Does this scenario sound familiar?

In today’s Industry 4.0 environment, these delays can be a thing of the past.

The digital difference: Automated asset tracking

Cloud-based asset management can integrate the various systems in your facility to make the maintenance process automated and seamless.

Imagine knowing exactly when your equipment goes down, and having a work order immediately created. The software then checks if the necessary parts needed for repair are in inventory, and if they’re not, it automatically creates a purchase order for them.

This level of efficiency equates to less downtime — and therefore, more cost savings — for a facility. Instead of waiting days for a missing bolt, internet-connected equipment and software can shave valuable time off the maintenance process.

Incorporating cloud-based tools into your facility

So how can you achieve this level of automation nirvana in your food processing plant? Contrary to what some may think, it doesn’t require investing in all brand-new equipment and infrastructure. Cloud-based tools can manage the data from your current equipment and allow your existing systems to communicate with each other efficiently.

You may be familiar with cloud computing services like Microsoft Azure, IBM Cloud and Amazon Web Services (AWS). These are popular platforms for facilities wanting to take advantage of the Industrial Internet of Things (IIoT) boom.

Here’s the thing, though: Anyone can purchase these tools, but if you don’t partner with experts who can program and connect your facility’s various systems, you’re missing out on the value of the technology. Knowing how to customize and integrate these tools for your particular needs is the key.

What does that look like? Here are the basic steps we take to help a food plant get started with smart asset management:

Understand the status quo and identify the facility’s pain points. Where is the technology needed? Why is equipment failing?

Analyze existing data points being collected (RPM, voltage, etc.)

Establish unique solutions for each piece of equipment that go beyond the software’s out-of-the-box capabilities

Schedule a demo and proof of concept to demonstrate ROI, such as the ability to predict when equipment will fail and the integration of various systems to provide alerts and notifications

Do you need an engineering partner to set up a cloud-based asset management system?

Since these cloud computing tools operate on machine learning, they require proper initial configuration to ensure they’re measuring the right data and working for your specific process.

Out of the box, a program like Microsoft Azure requires all the algorithms to be entered from scratch. Just feeding data to the Azure will not give you the correct outcome, because the program can’t make sense of your data or what you want to do with it. You must teach Azure to work for you.

That’s why teaming up with an experienced partner like Stellar is critical to maximizing results. Our application can help tailor to your specific refrigeration and processing needs, ensuring you maximize long-term ROI. We take a holistic approach and provide clients with an easy-to-understand portal where they can monitor alerts and metrics — even across multiple facilities — all in one place.

The power of predictive and prescriptive maintenance

For example, let’s consider a refrigeration compressor. The original equipment manufacturer (OEM) tests the equipment and provides estimates for how it will perform under certain voltages, temperatures, RPMs and other conditions. You can check for deviations off of this original curve, but that doesn’t tell you that something is wrong with a one percent deviation. Looking at a single compressor’s performance in a “data vacuum” isn’t very helpful.

However, by comparing the performance of your compressor against a large set of data from multiple compressors, the software can detect anomalies that humans would otherwise miss and anticipate problems before they happen.

So instead of conducting maintenance reactively (only after something breaks and creates a lot of downtime) or on a fixed schedule (every set number of days, even if maintenance isn’t technically needed yet), you can address problems proactively, saving time and money.

]]>http://stellarfoodforthought.net/get-started-with-cloud-based-asset-management-in-your-food-processing-plant/feed/04 Trends Food Companies Must Champion to Thrive in an Age of Disruptive Innovationhttp://stellarfoodforthought.net/4-trends-food-companies-must-champion-to-thrive-in-an-age-of-disruptive-innovation/
http://stellarfoodforthought.net/4-trends-food-companies-must-champion-to-thrive-in-an-age-of-disruptive-innovation/#respondThu, 02 May 2019 10:00:22 +0000http://stellarfoodforthought.net/?p=3799

If you’re a decision maker in the food manufacturing space, ask yourself these questions:

Does your company value sustainability and transparency in its processing?

Is your boardroom as diverse as your customer base?

Are your company’s leaders listening to those customers to anticipate what they want?

Is your company taking tangible steps to be innovative, or does it just say it is?

If you want to thrive — not just survive — in today’s market, you must be answering “yes” to these questions… or at least taking actionable steps toward a “yes.”

The food and beverage industry is changing more than ever before thanks to disruptive innovation, the internet, evolving customer values and more.

Don’t be the next Blockbuster, Kodak or Myspace. The key is to be proactive, not reactive. Where should you begin? Consider these leading trends shaping the industry.

Clean labels: Fresh products vs. shelf life

It’s no secret that consumers have increasingly favored more natural products with “cleaner” labels. However, some manufacturers have been reluctant to sacrifice shelf life (i.e., preservatives) to meet this demand.

The result? Those consumers have been willing to pay more for what they want and are taking their dollars elsewhere.

Meeting this demand for fresher food means rethinking processing and the supply chain. We’re seeing a greater focus on shipping efficiency and increased investment in tracking technology to monitor product through distribution.

This has led to the emergence of more vertically integrated supply chains and the growth of regional greenhouses. These climate-controlled greenhouses have sprouted in urban settings like Cincinnati and New York to shorten the distance between harvest and retail. Plus, climate change is reducing our ability to grow produce outside, leading to about 52.7 billion square feet of indoor farming space around the world.

Minimizing food waste

Today’s consumers care more about where their food comes from and how it’s made. They’re curious about the operations of the business and who they’re supporting with their dollars.

A lot of it is generational:Millennials and Gen Zers grew up in a digital era with immediate access to information, so they have a greater awareness of the industry that was once kept behind the proverbial curtain.

These consumers prioritize food waste and sustainability more than their predecessors — and some producers are keying in on this. For example, yogurt production requires a lot of water. The soury milk byproduct was often disposed of, but some processors are now finding ways to repurpose the liquid for other uses.

We’re seeing this reflected in some restaurants as well, with more chefs utilizing all components of a product to minimize food waste. Celery hearts may be used in one dish and the leaves may be used to garnish another, or kale leaves may form the base of a salad while the stems are used in a stew.

Diversity in the boardroom

Big Food brands have struggled to truly understand who their consumers are. Many of these companies are led by more traditional Baby Boomers who aren’t necessarily entrenched in how Millennial and Gen Z consumers think.

A major key to success today is making your boardroom diverse. While diversity includes gender and ethnicity, it’s also generational. Younger consumers are more global, have broader tastes and appreciate the flavors of other cultures.

Do you consider the input of Millennials and Gen Zers in your decision-making process? Do you encourage diversity in your C-suite? Your leadership and decision-making process must be a reflective mosaic that is true to the diversity of today’s consumer base.

Decreasing brand loyalty: Values and food insecurity

In general, Millennials and Gen Z consumers are less brand loyal than previous generations. Their loyalty is correlated to their values. Many times, if a brand deviates from their values, these shoppers will move on to another company that better aligns with what they believe.

We must also recognize that we’re at a unique juncture in our history in the United States, because food insecurity is more prevalent than ever. Processed foods have become the most cost-effective to produce, making less “healthy” foods the most affordable. And as the middle class has become hollowed out, food insecurity has encompassed an even larger group of people.

This significant number of consumers in lower income brackets still want the natural, healthy, clean-label foods as higher-income shoppers, but they can’t afford them. The question for food manufacturers: How do you scale these products that you once could provide to the middle class?

Denise Holloman is Principal & Chief Advisor at DAH Operations Advisors. In 2015, she retired from her position at General Mills as VP of Project Management Office and Global Continuous Improvement. Prior to joining General Mills, Holloman spent 12 years with Procter & Gamble in various operations management, maintenance/reliability, project management and systems engineering roles.

Most food and beverage companies aren’t against being more eco-friendly — it’s just that achieving sustainability in a food processing plant can be easier said than done.

The upfront investment associated with energy-efficient solutions, such as “green” building materials and equipment, can be difficult to justify. How do you know which energy-efficient options will provide the best return on investment?

As we observe Earth Day this week, let’s look at ways to invest in your food plant that are both good for the planet and provide a solid return on investment (ROI).

1. Properly insulate your building envelope

Facilities lose the most heat through their walls and ceilings, which is why proper insulation is so critical. Using materials that absorb heat, rather than release it, can greatly reduce long-term energy costs.

Here are three types of building envelope insulation that offer good ROI:

1. Precast concrete insulated panels — At Stellar, we generally recommend precast concrete insulated panels, which act as a sponge to absorb and store heat. These are the highest quality option because they’re built in a controlled environment at an off-site location, which ensures they’re properly constructed. Though they are more expensive than tilt-up panels, precast panels are often the best choice, especially when site limitations come into play.

2. Tilt-up concrete insulated panels — These offer the same thermal benefits as their precast counterparts, but they are built on-site. The downside to tilt-up panels is that they are more susceptible to construction errors and weather conditions, which can affect their quality and lead to higher energy costs.

3. Insulated metal panels (IMP) — Insulated metal panels work in the same way as concrete panels, except the foam insulation is sandwiched between metal, rather than concrete. While they are less expensive, they do not offer the same durability as concrete panels, and can be damaged more easily. IMP systems also lack the structural characteristics of concrete panels, and usually require additional steel framing and columns to help support roof loads.

Refrigeration costs can account for up to 60% of a facility’s total operating expenses, sometimes because refrigeration systems are unnecessarily working at full capacity. Installing a variable frequency drive (VFD) can help ensure your system never works harder than it needs to. By sensing temperature, pressure or flow, a VFD ramps down the appropriate pump or motor when a specified condition has been met, and ramps it back up once that condition falls outside its given threshold.

However, a VFD can be a significant investment, so it’s important to know which systems will benefit from this kind of regulator, and which will not. A VFD is not beneficial to a system that must run at full capacity at all times to maintain a specified condition. But, it is beneficial in a system that easily achieves a specified condition, yet continues to run at full capacity anyways.

Consider the difference in these two refrigeration systems:

Blast chiller — A blast chiller usually experiences a significant amount of heat exchange due to the frequent entry and exit of food products. As a result, it must run at full capacity at all times to maintain a proper freezing temperature. It’s not worth installing a VFD in such a system, as it would rarely be utilized.

Cold storage warehouse — A large distribution warehouse generally remains at a constant temperature for weeks at a time. Because the net heat load within the system rarely increases, the refrigeration system doesn’t need to run at full bore constantly. In this case, a VFD could provide significant energy savings by scaling down the refrigeration compressor motor.

3. Use LED lighting in processing areas

The debate over LED lighting almost always comes down to cost: Are LED lights really worth the extra expense? The key to optimizing lighting efficiency is knowing where to use LED lights in your facility.

LEDs are ideal for processing and packaging areas for three major reasons:

1. Longer lamp life — Most LED light fixtures have a lifetime of up to 10 years, which greatly reduces the downtime associated with replacing lighting in processing spaces.

2. Low energy use — LED lights use about 75 percent less energy than other types of fixtures. In processing and packaging areas that require constant lighting, LED lights create significant long-term savings.

3. Ability to withstand cold conditions — LED lights perform especially well in cold temperatures, which is necessary for most food processors. In comparison, fluorescent lighting is more likely to malfunction in extreme low temperatures.

Fluorescent lights are a viable option for your food plant’s less critical areas (employee welfare spaces and offices). To reduce energy use, it’s common to install occupancy sensors that automatically switch the lights off when the room is not occupied.

4. Think outside of the box when it comes to water conservation

Food plants use massive quantities of water for everything from processing to sanitation. It’s important to develop some sort of system for conserving water. Below are three water conservation tips you may not have considered before:

1. Reuse processing water for external sanitation — Water is often used to heat up or cool down a food product without coming in direct contact with it. Food processors can retain this water for cleaning items such as trucks, pallets and trolleys.

2. Use a water catchment system — Rather than allowing rainwater to drain into the ground, have a water catchment system pipe it into reservoirs to be used for things like irrigation and fire sprinklers.

3. Install flow meters on process equipment — A water control unit, or flow meter, helps ensure process equipment only uses a minimum quantity of water. It can regulate either flow rate or total volume, based on the equipment’s function.

5. Monitor your entire facility’s efficiency with a building automation system (BAS) controller

Most systems in a food plant — refrigeration, electrical, air conditioning, etc. — have built-in data collection controls that indicate performance efficiency. However, monitoring numerous unconnected systems can be difficult, and sometimes ineffective. One solution is to install a building automation system (BAS) controller to include every system in a comprehensive network, which offers significant energy reduction and other benefits, including:

Scheduled energy use — As the BAS controller becomes familiar with daily routines, it can identify patterns in energy usage. The controller can be optimized to regulate lighting and HVAC systems to match occupancy schedules, which maximizes efficiency.

Efficient facility management — BAS controllers collect real-time data on every process, which allows them to report system failures as they occur. This way, engineers don’t have to spend time diagnosing the problem, which reduces downtime and inefficiency. Owners can also use the data collected by the BAS system for accurate energy modeling.

BAS controllers are usually better suited for large plants containing numerous systems. Smaller plants may not have the need for an overarching network of automation controls.

Each food plant has unique needs, so sustainable solutions that work for one may not work for another. The key to making beneficial upgrades is understanding where there is room to improve, and just as importantly, where you can avoid unnecessary expenses.

Want to learn more about sustainable solutions for food processing? Leave a comment below or email me at tallsup@stellar.net.

Controlling dust is a major concern in food manufacturing, whether you’re roasting coffee beans, mixing spices or using flour as a release agent for your baked goods. Whenever there is potential dust in your processing environment, you want to capture it at the source.

Managing dust is critical for a variety of reasons:

Breathability — Excess dust in the atmosphere can make it difficult for plant personnel to breathe.

Explosions — Very fine explosive dust has a high surface-to-volume ratio, which can make it extremely combustible at a high concentration. The right conditions mixed with an ignition source could trigger an explosion in your facility. Lab tests can determine the category of explosiveness for a particular dust, which dictates the level of protection required.

Food safety — Dust can settle on and contaminate products before they are packaged. This is especially an issue when it comes to allergens, such as avoiding cross-contamination of flour on gluten-free products.

Dust collection systems serve as specialized “vacuum cleaners” to keep dust from overflowing into other areas. But how do you know which one is right for your specific process?

Industrial point-of-use vs. central dust collectors

There are two common systems that vary in the way that dust is collected. The right choice depends on the environment and nature of your processing.

Point-of-use dust collectors

A point-of-use, or unit, dust collector is a self-contained system that is placed at the source of dust creation. They are suitable for isolated, portable or frequently moved dust-producing operations.

Cons: They take up more total floor space than a central system, since you typically need multiple units throughout your processing area. Point-of-use collectors can be less efficient depending on the size of your space and volume of dust being created. Plus, the collected dust must be manually emptied frequently and the filters cleaned regularly.

Central dust collectors

Central dust collection systems are ideal for larger-scale operations in which a high volume of dust is created.

Pros: These collectors can capture dust from multiple locations with one vacuum source. They take up less floor space than multiple point-of-use units, and since there are fewer moving parts, maintenance is required less frequently.

Cons: Central systems are generally more expensive so they require a greater initial investment. Since they are larger and typically have collection areas greater than 10 cubic feet of volume, these systems require explosion venting, explosion suppression or other safety features to meet NFPA regulations. They also require permanent ducting with possible roof penetrations to exhaust the air, as well as permanent electrical and compressed air supplies.

Dust collector filters: Bags vs. cartridges

Whether you choose a point-of-use or central dust collection system, there are two common types of filters that can be used.

Bag filters — These filters generally require more maintenance because they must be washed and reinstalled properly. Depending on the air velocity and pulse frequency of your system, these cloth bags typically last about a year before they need to be replaced.

Cartridge filters — These filters don’t need to be serviced as often and can use reverse airflow to clean itself to a degree. The materials used in a cartridge filter are also more rigid, making them less susceptible to wear and tear compared to bag filters. Cartridge filters generally last up to five years. However, the pleats in cartridge filters are more susceptible to blinding on certain materials being collected. When that occurs, they are very difficult to clean and must sometimes be replaced.

Note: Some dusts are abrasive and may require special inlet materials and filter materials.

Recycling clean dust

In some cases, dust can be reused for other applications. We recently installed a central dust collection system at a doughnut plant that reclaims collected flour and sprinkles it onto the dough to minimize ingredient application. Of course, this can only be done with clean dust, typically with one type of product at a time, and with ensured quality control.

Both point-of-use and central dust collectors can be used to reclaim flour, but of course it’s not a necessity. Many facilities simply dispose of the dust, especially if it’s been contaminated.

Need more help determining the best dust collection strategy for your facility? Our experts are happy to help! Comment below or send me your questions at kwilson@stellar.net

The Industrial Internet of Things (IIoT) is revolutionizing how food manufacturing facilities operate, from processing to building maintenance and everything in between. Food and beverage companies have access to more data than ever before, and that’s helping them make more informed decisions.

Internet-connected sensors are the “eyes and ears” in a food plant, collecting all the data that makes those insights possible. These devices can measure a variety of inputs from electrical currents to vibrations to air temperature.

Stellar installs sensors in many of the modern facilities we design and construct today, but many owners have the same question: What exactly can I measure?

Let’s look at a few ways sensors can be used in your food plant:

Measuring

You can’t control what you don’t measure, and in a connected manufacturing facility, measurement starts with sensors. To get the most out of sensors, approach the selection and location from a cost control perspective.

1. Utility usage by product — Sensors at each branch of a utility can measure use by product line or product. Utility point-use and line usage can assist food processors looking to understand fixed and variable production costs. Analysis of this data with production data can help determine the optimal product mix to maximize profits.

2. Hidden quality drivers — With the sensor technology available today, individual pieces of equipment and facility conditions can be monitored to provide a wealth of information. Analysis of factors such as air and product flows and temperature, along with product quality data, can reveal underlying correlations and hidden drivers of quality.

Monitoring

Measuring is the first step, but monitoring needs to occur to coordinate equipment and personnel to ensure that the facility runs properly and efficiently. Monitoring and the accompanying automated controls aggregate sensor data into a system for fault response. Lowering response times and raising visibility reduces cost and quality impact from improper operating conditions.

Makeup air unit (MAU) or exhaust fan (EF) failure — Often, MAUs and EFs are interconnected to intentionally ensure they work together. When failures occur, monitoring systems send an alert notifying other equipment and/or personnel of the situation and automatically rebalance until the required maintenance is carried out.

HVAC air pressure— A significant decrease in air pressure within your HVAC system or ductwork can signal a blockage or filter problem. A dedicated sensor can detect this pressure change, making routine air filter changes easy to track. A monitoring system that alerts technicians to a filter problem can help avoid unscheduled downtime and unwanted quality issues.

Motor vibrations— If a motor is vibrating beyond its historical norm, a sensor can notify the equipment and/or plant personnel that something is moving toward failure and that the motor requires attention. Such a warning allows maintenance to address the problem as a scheduled task rather than waiting until a failure occurs during a production run.

Leaking pipes— You can install moisture-detecting sensors to detect pipe leaks in your facility. By the time most leaks are visible, substantial damage has already been done below the surface. Sensors can alert you to otherwise hidden leaks faster than ever before.

Maximizing

Maximizing the value of a connected facility built with IIoT data in mind goes beyond measuring and monitoring. Predictive (and deferred) maintenance plans can reduce the cost of both unscheduled downtime and excessive preventative maintenance. Facilities should work toward an IIoT strategy that drives a single “version of the truth” across all systems within a facility.

The future of maintenance: Predictive analytics and artificial intelligence

As sensors and building management systems become more connected, the true power of the data they collect comes into play. When sensors can collect data from multiple units of the same model across different locations, that aggregate data becomes more valuable than the individual data. In the big picture, that level and amount of data unlocks the potential for predictive analytics, machine learning and the applications of artificial intelligence to maintenance decisions.

This can be incredibly valuable for a large company with multiple facilities. For example, decision makers at the corporate headquarters could analyze performance data across multiple locations to determine which refrigeration units malfunction more frequently, allowing them to make more informed equipment investments moving forward.

This example only scratches the surface of what’s achievable as food plants truly begin harnessing the data they create. The possibilities are endless.

Want to learn more about making your facility “smarter” with sensors and internet-connected technology? Send me an email at mgriffith@stellar.net or call me at 904-260-2900.

Augmented reality (AR) is a powerful tool on Stellar’s job sites. Today’s AR technology is revolutionizing the way we design and build facilities, making construction projects more efficient and ultimately saving owners time and money.

Stellar leverages augmented reality in three major ways:

Help owners visualize their building on site before construction — AR helps owners see what their facility will look like in the context of the land where it’s being built. They can view a digital model of the building superimposed on their surroundings that updates and moves in real time. By using a tablet or HoloLens, they can look at the exterior or go room-by-room to see details as small as the view outside certain windows.

Manage quality assurance and validate the installation process— Construction crews can superimpose different layers of the design model onto the actual job site, allowing them to identify potential issues earlier and correct them faster. This makes work more efficient, saving time and potential costs.

Verify and visualize as-built conditions post-construction— If an owner wants to expand or build an addition to their space, augmented reality can be used to visualize where existing infrastructure is located in the walls. This makes it easier to tie into utilities like mechanical or plumbing.

The level of technology in augmented reality hardware has basically doubled in the last year, and we’re continuing to develop new ways to incorporate this tool into Stellar projects. The potential uses and future possibilities for AR technology are practically limitless.

]]>http://stellarfoodforthought.net/ar-on-the-construction-site-see-how-augmented-reality-benefits-builders-and-owners-video/feed/0Decision by Committee: The Pros and Cons of Group Decision-makinghttp://stellarfoodforthought.net/decision-by-committee-the-pros-and-cons-of-group-decision-making/
http://stellarfoodforthought.net/decision-by-committee-the-pros-and-cons-of-group-decision-making/#respondThu, 28 Mar 2019 10:00:04 +0000http://stellarfoodforthought.net/?p=3749

In recent years, more food and beverage companies have adopted a different perspective on decision-making. Rather than having one person making unilateral decisions, many businesses have shifted toward a “decision-by-committee” approach, where a small group of stakeholders are part of the process.

This trend is especially prevalent in larger companies that are adopting a more inclusive corporate culture. The goal is to foster greater pride and buy-in from employees by including diverse perspectives in decisions that affect them.

For example, I recently worked with several owners who utilized the decision-by-committee approach when Stellar was building their new food plant. These facilities are multimillion-dollar investments, and these leaders increasingly want to seek input from their employees who will be working in the facility and with the equipment every day.

The purpose behind the decision-by-committee process is admirable, but like anything, it has its advantages and disadvantages. To gain the most value from group decision-making, consider these pros, cons and best practices.

The advantages of decision-making by committee

Diverse ideas from a bigger audience

By nature, a decision-by-committee approach will yield contributions from more diverse perspectives, including from those who may have more experience.

Also, these committees typically involve members from various departments, such as:

Management

Engineering

Operations

Maintenance

IT

Including stakeholders from these different disciplines allows them to provide specific feedback on a more nuanced level. For example, when it comes to food plant design meetings, maintenance personnel can provide input on the installation of valves and the operations team can tweak the layout of processing lines.

Even if all the ideas can’t be implemented, your company is benefiting from hearing more options and can apply the best ones.

Vendors and contractors better understand your company’s needs

Having these diverse perspectives involved in big decisions allows your vendors, partners and contractors to better understand your company. In the case of our past food plant construction projects, the Stellar team established relationships with various team members instead of just one point of contact. This allowed us to better understand the various challenges and needs of different departments, resulting in greater trust from employees and a higher-quality project.

Decisions don’t hinge on one person’s availability

When you have one person making all the decisions, a project can come to a halt when that person is unavailable or out of the office. With a group, decisions can move forward even in the absence of a stakeholder — meaning a project timeline doesn’t hinge on one person’s schedule.

It’s worth noting that this point can also be a disadvantage if expectations and procedures for the committee aren’t set up properly. (More on that later in the “cons” section.)

Employees feel valued and collaboration is encouraged

Seeking input and feedback from various departments allows employees to feel heard and involved. Plus, these discussions generate dialogue and encourage a culture of collaboration. If executive leaders work together and value everyone’s opinions, mid-level managers and other employees across the company are more likely to follow suit.

The disadvantages of decision-making by committee

Longer decision-making process

The most obvious disadvantage of the decision-by-committee approach is that more stakeholders yields more discussion, which means it can take longer to arrive at an agreement. Plus, it can be more difficult to align the schedules of multiple people for a meeting.

This is often the downfall of many committees, but it doesn’t have to be. If you’re committed to group decision-making, build this extra time into your schedule so your next project doesn’t fall behind. (See best practices below!)

Varying communication styles

When you bring together a cross-section of people, it can be difficult to find an ideal communication method that works for everyone.

Do people reply to emails?

Are conference calls efficient?

What about texting for quick decisions?

How often do you need to meet in-person?

And it’s not just the mode of communication that can be challenging. Members from different generations may have different expectations when it comes to communication styles and how things are said, which can create friction.

Catching up latecomers

Sometimes the decision-making committee may change over the course of a project. A new person may be hired into the company or someone may change positions. This can slow down the process, because that person likely has to be brought up to speed and they may have feedback on decisions that have already been made. This can be tedious if not managed well.

Best practices for the decision by committee approach

Ensure you run an efficient and effective decision committee by following these tips:

1. Only make the committee as big as it needs to be — When assembling your decision-making group, only include the people critical to the process. It’s acceptable to have stakeholders from various departments, but one person can represent a division. Limit the committee to those intimately involved in the project and its outcome — if that’s only four people, don’t assemble a committee of 10.

2. Manage timelines and adapt accordingly— Be mindful of how long it takes the committee to make a decision and adjust as needed. For example, if you’re averaging three weeks to reach each major decision, adjust the project timeline to account for this.

3. Set new expectations for project deadlines — If your company is used to single-stakeholder decision-making, previous project timelines won’t apply in a decision-by-committee approach. Throw those old expectations out the window and create sensible deadlines according to this new decision-making process.

4. Base decisions on data — Supporting decisions with facts and hard data, rather than opinions or speculation, creates a shorter and more fluid decision-making process. There is less room for debate and uncertainty when decisions are based on facts.

5. Communicate the consequences of late decisions — Projects get off track when committees aren’t held accountable. Delayed decisions have real-world consequences. Remind the team of what’s at stake and what missed deadlines tangibly mean for the project. This can help avoid and/or solve “analysis paralysis” and stalemates.

6. Set a deadline for pulling the trigger — There comes a point when you must stop researching, discussing and thinking. Eventually a decision must be made. Set a time limit on how long discussions can last and establish hard deadlines for when final decisions must be made for each stage of the process.

7. Establish expectations for communication — As mentioned before, everyone communicates differently. Establish expectations for how the group will communicate (mode of communication, how often, ground rules, etc.) and be prepared for those to change over the course of the project. The key is to remain flexible, adapt and keep communication lines open.

8. Set multiple small goals instead of a single big one — Everyone in the group is working toward the same end goal, but getting there can be difficult if you’re not all on the same page along the way. Set small goals to stay on task. Establishing these milestones makes it easier to focus and sets your committee up for success. Don’t focus on December’s issues when you should be focusing on June’s.

Are you assembling a committee to build a new facility or renovate an existing one? We can help! Email me your questions at jgoode@stellar.net or leave a comment below.

The economy is thriving, the labor market is competitive and disruptive innovation is shaping the present and future of the food industry. Food plant owners are always looking for cost savings, especially in today’s fast-paced market. Could your packaging be a ripe opportunity?

Let’s look at a few considerations for optimizing your packaging process.

1. Switching from tape to glue for RSC packaging

There may be a cost-saving opportunity in your secondary packaging. Switching from tape to glue for sealing regular slotted containers (RSCs) could help your bottom line.

When taping cases, the flaps have to meet in the middle to ensure a proper seal. However with hot melt glue, the major and minor flaps can be shortened and still maintain proper closure. This is more cost-effective because the blank size is smaller, which in the end uses less corrugated cardboard.

Also, while tape sealing equipment is more affordable as an initial investment, the cases that run on the equipment (material cost) are a more expensive in the long term. For this reason, it’s always a good idea to look at the total cost — including equipment and materials — when purchasing equipment.

2. Changing from a lap seal to a fin seal

When it comes to primary packaging, opting for a fin seal over a lap seal can improve quality while decreasing cost, especially in stick packs.

A lap seal brings together two films that aren’t typically compatible with each other (such as OPP with LDPE), which is more difficult to seal, especially if product gets in the seals. On the other hand, a fin seal brings together the inside layers of the film, which are the same material and thus more compatible for sealing.

Fin seals are typically more cost-effective due to:

Less re-work needed due to seal failures, which leads to less packaging material waste, less product waste and fewer consumer complaints

Decrease in film thickness

More production up time

Lower material cost

3. Introducing a case packer

If you don’t use a case packer already, investing in one can greatly improve efficiency, especially if you’re trying to increase capacity. This equipment can boost speed on your packaging line by erecting cases and filling them with product. Not only does this yield long-term cost savings versus manual packing by plant personnel, but eliminating that labor also reduces employee injuries from repeat motion.

4. Investing in increased automation

In general, increasing automation at your food plant decreases overall waste. This technology requires a substantial upfront investment, but it can easily pay for itself in the long run if strategically implemented.

Automation isn’t just about boosting throughput and speed, either. For example, when you have someone manually packing cases, there are more opportunities for packaging to get damaged. There’s also an increased risk of quality problems, such as a worker placing the wrong flavor in the wrong carton or putting too much of one flavor in the carton, which could trigger a recall.

These are instances where materials and/or product can be wasted, which ultimately translates to lost dollars.

5. Monitoring and measuring packaging waste

Most facilities track packaging materials and waste to some degree, and some do it better than others. I’ve seen some companies that track cases, but rarely do they track items not included in the BOM like the actual tape or glue used to seal them.

At the end of the day, the more closely a facility monitors its waste, the more informed managers can be about increasing packaging efficiency. If you’re not tracking your material waste, it can be difficult to identify opportunities for improvement.

Are you lacking on your tracking and wondering where to begin? I’d start by analyzing your primary packaging, since it’s usually the most expensive packing component, and work downstream from there.

Set up regular meetings to review material waste numbers — perhaps every quarter — and include stakeholders from various departments.

6. Encouraging feedback from plant personnel

Your goal should always be continuous improvement, but you can’t get better without the input of the employees on the plant floor. These people are interacting with your product, packaging and process on a daily basis and often have some of the best ideas on how to improve it.

Create a culture of open communication and solicit feedback from plant personnel, whether that’s through a suggestion box, regular brainstorm meetings and/or incentives for providing new ideas.

Once you identify a cost-savings solution, you want to make sure it’s repeatable to maximize its potential. For example, if an employee finds a way to cut a 20-minute changeover down to five minutes, have that person write up a standard operating process (SOP) and train other operators.

There likely isn’t a glaring issue you’re overlooking, but it’s often little tweaks that can add up to bigger savings.

7. Establishing a preventative maintenance schedule

Don’t run your equipment into the ground until it breaks. A preventative maintenance program can help you schedule downtime instead of waiting for it to sneak up on you. Determine how often you need to replace parts before they break and create a schedule for routine maintenance.

This is a challenge for many facilities because the priority is always getting product out the door, but an unexpected breakdown during peak production hurts throughput more than scheduled downtime. Being proactive is always better than being reactive — and that doesn’t just apply to your packaging process.

Looking for specific guidance on how to optimize the packaging process at your facility? Email me at sobrien@stellar.net or give our team a call at 904-260-2900 (toll free: 800-488-2900).